Manufacturing method of reinforcing member and manufacturing method of cushion body using reinforcing member

Abstract

To provide a manufacturing method of reinforcing members capable of reducing work processes for forming a three-dimensional reinforcing member and simplifying the management of the work processes, and manufacturing method of a cushion body using the reinforcing member.SOLUTION: A manufacturing method of reinforcing members 3 for forming a reinforcing member 3 to be integrated with a back side of a cushion pad into a three-dimensional shape from a sheet-like material 30, the manufacturing method of the reinforcing member 3 includes: using a molding tool 4 including heaters 44 in an upper mold part 41 and a lower mold part 42; disposing a sheet-like material 30 in the lower mold part 42; clamping the sheet-like material 30 between the upper mold part 41 and the lower mold part 42 of the molding tool 4 heated by the heaters 44; and deforming at least a part of the sheet-like material 30 to form the three-dimensional reinforcing member 3.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a reinforcing member and a method for manufacturing a cushion body using the reinforcing member. [Background technology]

[0002] For example, a cushion body used in a vehicle or the like may have a reinforcing member disposed on the back side of a cushion pad made of a foam molded body. The reinforcing member is made of a nonwoven fabric or the like in which a fibrous thermoplastic resin is formed into a sheet shape. When foam molding of the cushion pad is performed using a mold, the reinforcing member is often in the form of a sheet and disposed along the mold.

[0003] On the other hand, when foam molding of a cushion pad is performed using a mold, a reinforcing member formed into a three-dimensional shape may be used. For example, in the manufacturing method of a nonwoven fabric molded body described in Patent Document 1, a fabric sheet made of nonwoven fabric is molded into a nonwoven fabric molded body using a mold. In this manufacturing method of a nonwoven fabric molded body, after heating the fabric sheet made of nonwoven fabric, incisions are made in the molding surface of the heated fabric sheet, and the fabric sheet is molded into a three-dimensional shape using the mold. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2015-16036 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the method for producing a nonwoven fabric molded body of Patent Document 1, the process of heating the dough sheet and the process of forming the dough sheet into a three-dimensional shape are performed separately. Therefore, there are many work steps for forming the nonwoven fabric molded body, and the management of the work steps is complicated. Therefore, further ingenuity is required to form a reinforcing member such as a nonwoven fabric molded body having a three-dimensional shape with fewer work steps.

[0006] The present invention has been made in consideration of such problems, and aims to provide a method for manufacturing a reinforcing member that can reduce the number of work processes required to form a reinforcing member with a three-dimensional shape and simplify the management of the work processes, and a method for manufacturing a cushion body using a reinforcing member. [Means for solving the problem]

[0007] One aspect of the present invention is A manufacturing method for forming a reinforcing member to be integrated into a rear surface of a cushion pad from a sheet-like material into a three-dimensional shape, comprising the steps of: A molding die having an upper mold portion and a lower mold portion, at least one of the upper mold portion and the lower mold portion having a built-in heater is used, A preparation step of preparing the sheet-like material having a shape corresponding to the developed shape of the back surface of the cushion pad; a placement step of placing the sheet material on the upper mold portion or the lower mold portion; and a forming step of sandwiching the sheet material between the upper mold part and the lower mold part of the mold heated by the heater and deforming at least a part of the sheet material to form the reinforcing member having a three-dimensional shape. fruit, A magnet is provided on a molding surface of the upper mold part or a molding surface of the lower mold part of the mold, In the positioning step, the sheet material is positioned on the molding surface on which the magnet is provided by attracting a magnetic body provided on the sheet material to the magnet. The present invention relates to a method for manufacturing a reinforcing member.

[0008] Another aspect of the present invention is A method for manufacturing a cushion body using the reinforcing member having a three-dimensional shape manufactured by the method for manufacturing a reinforcing member, comprising the steps of: A cushion body molding die having an upper mold part and a lower mold part is used, a placement step of placing the reinforcing member on the upper mold part that is opened relative to the lower mold part; an injection step of injecting a foaming raw material constituting a cushion pad into the lower mold part; and a molding process of closing the upper mold part against the lower mold part, and foaming the foaming raw material in a cavity formed by the upper mold part and the lower mold part, to form the cushion pad having the reinforcing member integrated on its back surface. Effect of the Invention

[0009] (Method of manufacturing reinforcing member) In the method for manufacturing a reinforcing member according to the above aspect, a mold is used in which a heater is built into at least one of the upper and lower mold parts. In the forming step, a sheet-like material is sandwiched between the upper and lower mold parts of the mold heated by the heater. At this time, a part of the sheet-like material is deformed by the heat of the mold, and a reinforcing member having a three-dimensional shape is formed.

[0010] With this configuration, the sheet material can be heated by the molding die used in the forming process of forming the sheet material. Therefore, according to the manufacturing method of the reinforcing member of the one aspect, it is possible to reduce the number of steps for forming the reinforcing member having a three-dimensional shape, and to simplify the management of the steps. In the method for producing a reinforcing member according to the above aspect, a magnet is provided on the molding surface of the upper mold part or the molding surface of the lower mold part of the mold. In the positioning step, the sheet material is placed on the molding surface on which the magnet is provided by attracting a magnetic body provided on the sheet material to the magnet. With this configuration, it is possible to prevent the sheet material placed on the molding surface of the mold from shifting out of position.

[0011] (Manufacturing method of cushion body) In the method for manufacturing a cushion body of the other aspect, a three-dimensional reinforcing member manufactured by the method for manufacturing a reinforcing member of the one aspect is used. In the positioning step, the reinforcing member can be easily positioned at a desired position on the upper mold part. In the molding step, the cushion pad with the reinforcing member arranged thereon is molded, so that the reinforcing member is arranged at a desired position on the back surface of the cushion pad while suppressing the occurrence of wrinkles, and a cushion body in which the reinforcing member is integrated along the back surface shape of the cushion pad can be manufactured. [Brief description of the drawings]

[0012] [Figure 1] FIG. 2 is an explanatory diagram showing the cushion body according to the first embodiment, in which a reinforcing member is integrated with the rear surface of the cushion pad, as viewed from the rear side. [Diagram 2] FIG. 4 is an explanatory diagram showing the reinforcing member according to the first embodiment as viewed from the back side. [Diagram 3] FIG. 2 is a perspective view of a mold having an upper mold portion, a lower mold portion, and a sliding mold portion according to the first embodiment. [Figure 4] 4 is an explanatory diagram showing a molding die having an upper die portion, a lower die portion and a sliding die portion according to the first embodiment, in a cross section corresponding to the cross section IV-IV in FIG. [Diagram 5] 4 is an explanatory diagram showing a molding die having an upper die portion, a lower die portion and a sliding die portion according to the first embodiment, in a cross section corresponding to the VV cross section of FIG. [Figure 6] FIG. 2 is an explanatory diagram showing a sheet-like material constituting a reinforcing member according to the first embodiment. [Figure 7] FIG. 2 is an explanatory diagram showing a state in which a plurality of sheet materials are cut out from an original roll according to the first embodiment. [Figure 8] FIG. 8 is an explanatory diagram showing, in an enlarged scale, a portion enclosed by a frame VIII in FIG. 4, illustrating a state in which a magnetic body of a sheet-shaped material is attracted to a magnet provided in a forming die according to the first embodiment. [Figure 9] FIG. 2 is an explanatory diagram showing a state in which a joint is formed on a sheet material according to the first embodiment. [Figure 10] FIG. 4 is an explanatory diagram showing a state in which another bonded portion is formed on the sheet material according to the first embodiment. [Figure 11] FIG. 11 is an explanatory diagram showing a cushion body molding die having an upper mold part and a lower mold part according to a second embodiment, in a cross section taken along the left-right direction. [Figure 12] FIG. 11 is an explanatory diagram showing a cushion body molding die having an upper mold part and a lower mold part according to a second embodiment, in a cross section taken along the vertical direction. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] A preferred embodiment of the method for producing the reinforcing member and the method for producing a cushion body using the reinforcing member will now be described. In the method for producing a reinforcing member according to the above aspect, the molding die may further include a slide die part that is slidable in a direction intersecting a direction in which the upper die part and the lower die part are opened and closed, which makes it easy to form a reinforcing member having a complex shape, such as a so-called undercut shape.

[0014] In the forming step, the heater may raise the surface temperature of the forming surface of the mold above the softening point of the sheet-like material. With this configuration, at least a portion of the sheet-like material can be quickly softened and easily deformed.

[0015] In addition, after the forming step, a cutting step may be performed in which a part of the reinforcing member is cut off to form a product shape for integration with the rear surface of the cushion pad. With this configuration, the outer shape of the reinforcing member can be adjusted.

[0016] In the forming step, a joint portion may be formed in which a part of the sheet material is overlapped and joined to the reinforcing member, whereby occurrence of wrinkles in the reinforcing member can be suppressed.

[0017] In the forming step, the sheet material may have a slit formed therein, and this configuration allows the reinforcing member to be formed three-dimensionally with a good appearance.

[0019] A preferred embodiment of the method for manufacturing the reinforcing member and the method for manufacturing a cushion body using the reinforcing member will be described with reference to the drawings. <Embodiment 1> 1 and 2, the manufacturing method of the reinforcing member 3 in this embodiment is to form the reinforcing member 3 to be integrated with the back side surface 201 of the cushion pad 2 into a three-dimensional shape from a sheet-like material 30. In the manufacturing method of the reinforcing member 3, as shown in Figs. 3 to 5, a preparing step, a arranging step, and a forming step are performed using a molding die 4 having an upper die portion 41 and a lower die portion 42 in which heaters 44 are built.

[0020] In the preparation step, as shown in Figures 6 and 7, a sheet-like material 30 having a shape corresponding to the developed shape of the back side surface 201 of the cushion pad 2 is prepared. In the arrangement step, as shown in Figure 8, the sheet-like material 30 is arranged on the lower mold portion 42. In the formation step, as shown in Figures 4 and 5, the sheet-like material 30 is sandwiched between the upper mold portion 41 and the lower mold portion 42 of the molding die 4 heated by a heater 44, and at least a portion of the sheet-like material 30 is deformed to form a reinforcing member 3 having a three-dimensional shape.

[0021] A method for producing the reinforcing member 3 of this embodiment will be described in detail below. (Reinforcing member 3 and cushion body 1) As shown in Figs. 1 and 2, the reinforcing member 3 is disposed on the back surface 201 of the cushion pad 2 to constitute the cushion body 1. Fig. 1 shows the cushion body 1 as viewed from the back side, and Fig. 2 shows the reinforcing member 3 as viewed from the back side. In Figs. 1 and 2, the upper side is indicated by reference character H1, and the lower side is indicated by reference character H2. The back side is indicated by reference character D1, and the front side is indicated by reference character D2. The cushion body 1 can be used to constitute a vehicle seat or the like. The reinforcing member 3 is constituted by a nonwoven fabric or the like in which a fibrous thermoplastic resin is formed into a sheet shape. The reinforcing member 3 is used to reduce the generation of abnormal noise when the cushion body 1 is disposed on a framework such as a seat frame, by contacting the framework.

[0022] The cushion body 1 of this embodiment constitutes the backrest of a vehicle seat. The cushion pad 2 of the cushion body 1 has a main body 21 and folded-back portions 221 formed by folding back an upper portion 211 and left and right side portions 212 of the main body 21 to the rear side. A bag-shaped portion 22 connected to the folded-back portions 221 is formed in the upper portion 211 and left and right side portions 212 of the cushion pad 2. The rear side of the main body 21 of the cushion pad 2 is located on the rear side in the front-rear direction of the vehicle.

[0023] The rear side surface 201 of the cushion pad 2 includes the inner side surface as the rear side surface 201 of the bag-shaped portion 22 (folded-back portion 221) in addition to the rear side surface 201 of the main body portion 21. The reinforcing member 3 is disposed on almost the entire rear side surface 201 of the cushion pad 2. The reinforcing member 3 has a shape that conforms to the shape of the rear side surface 201 of the cushion pad 2. The reinforcing member 3 has a main body portion 31 disposed on the rear side surface 201 of the main body portion 21 of the cushion pad 2, and a bag-shaped portion 32 disposed on the rear side surface 201 of the bag-shaped portion 22 of the cushion pad 2. The bag-shaped portion 32 has a shape in which folded-back portions 321 formed by folding back an upper portion 311 and left and right side portions 312 of the main body portion 31 to the rear side are connected.

[0024] A plurality of deformation openings 341 for facilitating deformation of the cushion body 1 are formed in the main body 31 of the reinforcing member 3 in an elongated shape along the up-down direction. In addition, an airbag opening 342 for facilitating the escape of an airbag disposed in the seat to the outside of the seat when activated is also formed in one side of the reinforcing member 3.

[0025] 2 and 6, the reinforcing member 3 is formed by three-dimensionally deforming and partially joining a sheet-like material 30. The sheet-like material 30 has a portion where a slit 331 is provided at a position where a mountain-shaped folded portion 33 is to be formed. As shown in FIG. 10, the slit 331 is provided in order to form the folded portion 33 where portions of the sheet-like material 30 located on both sides of the slit 331 are overlapped and joined two or more times. The slit 331 allows the sheet-like material 30 to be folded three-dimensionally with a good appearance.

[0026] 6 and 7, the sheet-like material 30 used in the manufacturing method of the reinforcing member 3 is formed into a predetermined sheet shape by a preparation step performed before the arrangement step. The sheet-like material 30 arranged in the forming die 4 in the arrangement step is cut out from a long original web 300 in the preparation step into a predetermined sheet shape close to the unfolded shape of the reinforcing member 3. The sheet-like material 30 cut out from the original web 300 has openings 341 for deformation, openings 342 for an airbag, holes 343 for inserting a headrest, slits 331, etc. formed therein.

[0027] Since the sheet material 30 used in the arrangement step is cut into a predetermined sheet shape, a plurality of sheet materials 30 can be cut out side by side adjacent to each other in the original roll 300. This configuration can reduce the portion of the original roll of sheet material 30 that is not used and is discarded, and can improve the yield of sheet material 30.

[0028] The fibrous thermoplastic resin constituting the sheet-like material 30 has a softening point of 100° C. or less so that it can be quickly softened by the molding die 4. The heater 44 in the molding die 4 is configured to heat the sheet-like material 30 to a temperature equal to or higher than the softening point. The softening point is the temperature at which a material such as a thermoplastic resin starts to deform or soften when heated. In other words, the softening point, also called the softening temperature, indicates the temperature at which the material changes from a hard state to a soft, plastically deformable state.

[0029] 8, magnetic bodies 36 are provided on appropriate portions of the edge of the sheet-like material 30 to facilitate positioning along the molding surface 401 of the mold 4. The magnetic bodies 36 are attracted to magnets 45 provided on the molding surface 401 of the mold 4 and are used to hold the sheet-like material 30 in position relative to the mold 4. Examples of the magnetic bodies 36 that can be used include staples such as a stapler, iron powder tape, and magnets.

[0030] (Mold 4) As shown in Figs. 3 to 5, the molding die 4 for forming the reinforcing member 3 into a three-dimensional shape is composed of an upper mold part 41, a lower mold part 42, and a slide mold part 43. The molding die 4 is configured to form the reinforcing member 3 in a state in which the front side surface 302 of the main body part 31 faces upward. The upper mold part 41 is configured to press down the front side surface 302 of the reinforcing member 3, and the lower mold part 42 is configured to support the back side surface 301 of the reinforcing member 3. The slide mold part 43 is formed divided into three parts so as to press down the top part 311 and the left and right side parts 312 of the reinforcing member 3 in a state in which it is fitted to the upper mold part 41 and the lower mold part 42 from the side.

[0031] The molding surface 401 of the lower mold part 42 is formed into a shape that follows the three-dimensional shape of the reinforcing member 3. As shown in Fig. 3 to Fig. 5 and Fig. 8, at a position of the lower mold part 42 corresponding to the bag-shaped part 32 (folded part 321), a protruding part 421 is formed in which the upper surface protrudes upward and protrudes outward from the central part of the lower mold part 42.

[0032] In this embodiment, the portion of the sheet material 30 where the bag-shaped portion 32 (folded-back portion 321) is to be formed is disposed on the molding surface 401 of the raised portion 421 of the lower mold portion 42. A magnet 45 for attracting the magnetic body 36 of the sheet material 30 is provided on the molding surface 401 of the raised portion 421. The magnet 45 in this embodiment is embedded in the raised portion 421 with a portion of its surface exposed to the molding surface 401. In other words, a portion of the molding surface 401 of the raised portion 421 is formed by the surface of the magnet 45.

[0033] The magnets 45 are disposed in a plurality of dispersed locations on the molding surface 401 of the raised portion 421. The magnets 45 are provided on the molding surface 401 of the raised portion 421 in correspondence with the positions of the magnetic bodies 36 on the edge of the sheet-like material 30. The magnetic bodies 36 of the sheet-like material 30 are attracted to the magnets 45 of the raised portion 421 of the lower mold portion 42, so that the sheet-like material 30 can be stably disposed at a target position on the lower mold portion 42 in a state in which it is unlikely to shift out of position.

[0034] As shown in Fig. 3, the molding surface 401 of the upper mold part 41 is formed in a shape that faces the molding surface 401 of the lower mold part 42 and sandwiches the sheet-like material 30. The slide mold part 43 is slidable in a direction intersecting (in this embodiment, perpendicular to) the opening and closing direction K of the upper mold part 41 and the lower mold part 42. The three slide mold parts 43 sandwich the sheet-like material 30 between the lower mold part 42 or the upper mold part 41, thereby forming a bag-shaped part 32 in the sheet-like material 30. The bag-shaped part 32 forms a so-called undercut shape, and can be formed and released by using the slide mold part 43.

[0035] 2, 4, and 5, the slide mold part 43 that presses down the upper part of the reinforcing member 3 mainly forms the folded-back part 321 of the upper part 311 of the reinforcing member 3. The pair of slide mold parts 43 that press down the left and right side parts 312 of the reinforcing member 3 mainly form the folded-back parts 321 of the left and right side parts 312 of the reinforcing member 3.

[0036] The heater 44 in this embodiment is embedded in each of the upper mold part 41, the lower mold part 42, and the slide mold part 43. The heater 44 may be embedded in a position close to the molding surface 401 in the upper mold part 41, the lower mold part 42, and the slide mold part 43. The heater 44 in this embodiment is configured with hot water piping through which hot water used in factories flows. Note that, instead of using hot water piping, an electric heater or a plate heater that generates heat by electricity, or an oil heater that uses heated oil as a heat medium, etc. may be used for the heater 44. By embedding the heater 44 in the molding die 4 as in this embodiment, the space required for installing the device can be made smaller than when a heating device is provided separately from the molding die 4.

[0037] (Details of the manufacturing method of the reinforcing member 3) When forming the sheet-like material 30 into the reinforcing member 3 having a three-dimensional shape, a preparation step, an arrangement step, and a formation step are performed. As shown in Figs. 6 and 7, in the preparation step, a long raw material 300 is pressed (cut out) to form a plurality of sheet-like materials 30. As shown in Figs. 3 and 8, in the arrangement step, the sheet-like material 30 is arranged on the lower mold section 42. At this time, the plurality of magnetic bodies 36 in the sheet-like material 30 are attracted to the plurality of magnets 45 in the raised portions 421, thereby fixing the sheet-like material 30 to the lower mold section 42.

[0038] In the arrangement step, the portion of the sheet-like material 30 where the bag-shaped portion 32 (folded portion 321) is to be formed is arranged on the raised portion 421 by folding it to match the shape of the raised portion 421 of the lower mold portion 42. As shown in Figs. 2 and 9, the sheet-like material 30 has a portion where a joint 37 is to be formed near the corner 313 between the upper portion 311 and the left and right side portions 312. The portion where the joint 37 is to be formed is arranged on the raised portion 421 by folding a part of the sheet-like material 30 so as to overlap three or more times. The joint 37 makes it possible to form the reinforcing member 3 into a desired shape from the sheet-like material 30 in a later forming step while suppressing the occurrence of wrinkles in the reinforcing member 3.

[0039] 2, when the sheet-like material 30 is arranged three-dimensionally on the raised portion 421, a portion where a slit 331 is provided as a cut is set near the lower portion of one side portion 312. The portion where the slit 331 is provided is arranged on the raised portion 421 by folding the portions of the sheet-like material 30 located on both sides of the slit 331 so as to overlap twice or more.

[0040] In the arrangement step, the upper mold part 41, the lower mold part 42, and the slide mold part 43 are heated by the heater 44 embedded in the upper mold part 41, the lower mold part 42, and the slide mold part 43. In this embodiment, while the arrangement step and the formation step are being performed, hot water constantly flows through the hot water pipe constituting the heater 44, and the upper mold part 41, the lower mold part 42, and the slide mold part 43 are constantly heated.

[0041] In particular, in the forming process, the heater 44 heats the surface temperatures of the molding surfaces 401 of the upper mold portion 41, the lower mold portion 42, and the slide mold portion 43 to be higher than the softening point of the sheet-like material 30. The softening point of the sheet-like material 30 is in the range of 70°C or higher and lower than 100°C, and the heater 44 in this embodiment heats the upper mold portion 41, the lower mold portion 42, and the slide mold portion 43 to 100°C.

[0042] 4 and 5, in the forming process, after the sheet-like material 30 is placed on the lower mold section 42, the multiple slide mold sections 43 are closed on the lower mold section 42, and the upper mold section 41 is closed on the lower mold section 42 and the multiple slide mold sections 43. Then, the sheet-like material 30 is sandwiched between the upper mold section 41, the lower mold section 42, and the multiple slide mold sections 43. Depending on the shape of the reinforcing member 3 to be manufactured, after the sheet-like material 30 is placed on the lower mold section 42, the upper mold section 41 may be closed on the lower mold section 42, and the multiple slide mold sections 43 may be closed on the lower mold section 42 and the upper mold section 41.

[0043] In the forming process, the sheet-like material 30 is sandwiched between the heated upper mold part 41, lower mold part 42, and multiple slide mold parts 43, and the sheet-like material 30 is softened by the heat transmitted from the upper mold part 41, lower mold part 42, and multiple slide mold parts 43. When the sheet-like material 30 has softened, it is in an appropriately molten state.

[0044] The softened sheet material 30 is deformed along each of the forming surfaces 401 of the upper mold portion 41, the lower mold portion 42 and the multiple slide mold portions 43, and is press-molded by each of the forming surfaces 401. At this time, as shown in Fig. 2, near the corners 313 between the upper portion 311 and the left and right side portions 312 of the bag-shaped portion 32 of the sheet material 30, a joint portion 37 is formed in which a part of the sheet material 30 is joined in a triple or more overlapping manner, as shown in Fig. 9. At this time, as shown in Fig. 2, near the lower portion of one side portion 312 of the sheet material 30, a joint portion 38 is formed in which parts of the sheet material 30 located on both sides of the slit 331 are joined in a double or more overlapping manner, as shown in Fig. 10.

[0045] Next, in the forming process, the sheet-like material 30 is held between the upper mold portion 41, the lower mold portion 42, and the multiple slide mold portions 43 for a predetermined period of time. As a result, a three-dimensional reinforcing member 3 is formed from the sheet-like material 30. Thereafter, the upper mold portion 41 and the multiple slide mold portions 43 open (retract) relative to the lower mold portion 42, and the reinforcing member 3 is removed from the lower mold portion 42.

[0046] (Action and effect) In the manufacturing method of the reinforcing member 3 of this embodiment, a molding die 4 having heaters 44 built in the upper die portion 41, the lower die portion 42, and the plurality of slide die portions 43 is used. Then, in the forming step, the sheet-like material 30 is sandwiched between the upper die portion 41, the lower die portion 42, and the plurality of slide die portions 43 heated by the heater 44. At this time, parts of the sheet-like material 30 are melted and joined by the heat of the upper die portion 41, the lower die portion 42, and the plurality of slide die portions 43, and the reinforcing member 3 having a three-dimensional shape is formed.

[0047] With this configuration, the sheet-like material 30 can be heated by the molding die 4 used in the forming step of forming the sheet-like material 30. Therefore, according to the manufacturing method of the reinforcing member 3 of this embodiment, it is possible to reduce the number of work steps for forming the reinforcing member 3 having a three-dimensional shape, and it is possible to simplify the management of the work steps.

[0048] <Embodiment 2> This embodiment describes a manufacturing method for a cushion body 1 using a reinforcing member 3 having a three-dimensional shape manufactured by a manufacturing method for the reinforcing member 3. In the manufacturing method for the cushion body 1, a positioning step, an injection step, and a molding step are performed to mold the cushion body 1 in which the reinforcing member 3 is integrated with the rear surface 201 of the cushion pad 2. In the manufacturing method for the cushion body 1, the cushion pad 2 is foam-molded so that the reinforcing member 3 having a three-dimensional shape is integrated with the rear surface 201.

[0049] 11 and 12, in the manufacturing method of the cushion body 1, a cushion body molding die 5 having an upper mold part 51 and a lower mold part 52 for molding the cushion body 1 is used. The upper mold part 51 is configured to mold the back side surface 201 of the cushion pad 2 on which the reinforcing member 3 is disposed, and the lower mold part 52 is configured to mold the front side surface of the cushion pad 2.

[0050] In the placement step, the reinforcing member 3 is placed in the upper mold part 51 which is opened relative to the lower mold part 52. At this time, since the reinforcing member 3 is formed in a three-dimensional shape, the reinforcing member 3 can be easily placed at a desired position in the upper mold part 51. Next, in the injection step, the foaming raw material 20 which constitutes the cushion pad 2 is injected into the lower mold part 52. The foaming raw material 20 is a liquid thermoplastic resin raw material containing a foaming agent.

[0051] Next, in the molding step, the upper mold part 51 is closed relative to the lower mold part 52. Then, in the cavity 53 formed by the upper mold part 51 and the lower mold part 52, the foaming raw material 20 foams and flows between the lower mold part 52 and the reinforcing member 3, and the foaming raw material 20 fills the cavity 53. As a result, the cushion pad 2 having the reinforcing member 3 integrated with the back surface 201 is molded in the cavity 53, and the cushion body 1 having the cushion pad 2 and the reinforcing member 3 is manufactured. Thereafter, the upper mold part 51 is opened relative to the lower mold part 52, and the manufactured cushion body 1 is taken out from the upper mold part 41.

[0052] In the manufacturing method of the cushion body 1 of this embodiment, a reinforcing member 3 having a three-dimensional shape manufactured by the manufacturing method of the reinforcing member 3 is used. In the arranging step, the reinforcing member 3 can be easily arranged at a desired position on the upper mold part 51. In the molding step, the cushion pad 2 having the reinforcing member 3 arranged thereon is molded, and the reinforcing member 3 having a desired shape is arranged at a desired position on the rear surface 201 of the cushion pad 2. Therefore, the occurrence of wrinkles in the reinforcing member 3 is suppressed even during molding of the cushion pad 2, and the cushion body 1 having the reinforcing member 3 integrated without wrinkles along the shape of the rear surface 201 of the cushion pad 2 can be manufactured.

[0053] The reinforcing member 3 of this embodiment is similar to that shown in embodiment 1. In this embodiment, too, components denoted by the same reference numerals as those in embodiment 1 are similar to those in embodiment 1.

[0054] <Other embodiments> The reinforcing member 3 having a three-dimensional shape may have unnecessary ends cut off after being formed in the manufacturing method of the reinforcing member 3. More specifically, after the forming step in the manufacturing method of the reinforcing member 3, a cutting step may be performed in which a part of the reinforcing member 3 having a three-dimensional shape is cut off to form the reinforcing member 3 into a product shape for integration with the rear side surface 201 of the cushion pad 2.

[0055] In this case, the outer shape of the reinforcing member 3 can be adjusted by cutting off a part of the reinforcing member 3. In addition, in this case, when preparing the sheet-shaped material 30, the sheet-shaped material 30 may be formed in a rough shape, which makes it easier to prepare the sheet-shaped material 30.

[0056] Furthermore, when the reinforcing member 3 does not have a bag-shaped portion 32 or when the reinforcing member 3 has a simple shape, the slide mold portion 43 becomes unnecessary, and the molding die 4 may be formed of the upper mold portion 41 and the lower mold portion 42. For example, when manufacturing the reinforcing member 3 of the cushion body 1 that constitutes the sitting portion of the seat, the slide mold portion 43 may become unnecessary.

[0057] The present invention is not limited to the respective embodiments, and further different embodiments can be configured without departing from the spirit of the present invention. The present invention also includes various modifications, modifications within the scope of the equivalents, and the like. [Explanation of symbols]

[0058] 1 Cushion body 2 Cushion pad 20 Foaming materials 201 Back side 21 Main body 22 Bag shaped part 221 Turn-back section 3 Reinforcement members 30 Sheet material 31 Main body 32 Bag shaped part 321 Turn-back section 33 Bending section 331 Slit 36 Magnetic material 37,38 Joint 4 Molding mold 401 Molding surface 41 Upper part 42 Lower die section 421 Ridge 43 Slide type part 44 Heater 45 Magnet 5. Cushion body molding die 51 Upper mold part 52 Lower mold part 53 Cavity

Claims

1. A manufacturing method for forming a reinforcing member to be integrated into a rear surface of a cushion pad from a sheet-like material into a three-dimensional shape, comprising the steps of: A molding die having an upper mold portion and a lower mold portion, at least one of the upper mold portion and the lower mold portion having a built-in heater is used, A preparation step of preparing the sheet-like material having a shape corresponding to the developed shape of the back surface of the cushion pad; a placement step of placing the sheet material on the upper mold portion or the lower mold portion; a forming step of sandwiching the sheet material between the upper mold part and the lower mold part of the mold heated by the heater and deforming at least a part of the sheet material to form the reinforcing member having a three-dimensional shape, A magnet is provided on a molding surface of the upper mold part or a molding surface of the lower mold part of the mold, In the placing process, a magnetic body provided on the sheet-like material is attracted to the magnet, thereby placing the sheet-like material on the molding surface on which the magnet is provided. This is a method for manufacturing a reinforcing member.

2. The method for manufacturing a reinforcing member according to claim 1 , wherein the molding die further comprises a slide die portion that is slidable in a direction intersecting a direction in which the upper die portion and the lower die portion are opened and closed.

3. The method for producing a reinforcing member according to claim 1 or 2, wherein in the forming step, the surface temperature of the molding surface of the mold is increased by the heater to a temperature higher than a softening point of the sheet-like material.

4. The method for manufacturing a reinforcing member according to any one of claims 1 to 3, further comprising a cutting step of cutting out a part of the reinforcing member to form the reinforcing member into a product shape to be integrated with a rear surface of the cushion pad, after the forming step.

5. The method for producing a reinforcing member according to any one of claims 1 to 4, wherein in the forming step, a joint portion is formed in the reinforcing member by overlapping and joining a part of the sheet material.

6. The method for producing a reinforcing member according to any one of claims 1 to 5, wherein the sheet-like material having slits formed therein is used in the forming step.

7. A method for manufacturing a cushion body using a three-dimensional reinforcing member manufactured by the method for manufacturing a reinforcing member according to any one of claims 1 to 6, comprising the steps of: A cushion body molding die having an upper mold part and a lower mold part is used, a placement step of placing the reinforcing member on the upper mold part that is opened relative to the lower mold part; an injection step of injecting a foaming raw material constituting a cushion pad into the lower mold part; and a molding process of closing the upper mold part against the lower mold part, and foaming the foaming raw material in a cavity formed by the upper mold part and the lower mold part, to form the cushion pad having the reinforcing member integrated on its back surface.

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